Manufacture of glazed ceramic bodies



April 25, 1944. G. J. BAIR MANUFACTURE OF GLAZED CERAMIC BODIES origial Filed Nov. 29, 1958 7 sheets-sheet 1 April 25 1944 G. J. BAIR 2,347,535

MANUFACTURE OF GLAZED CERAMIC BODIES Original Filed N0v. 29, '1938 '7 Sheets-Shee. 2

April 25, 1944. G. J. BAIR MANUFACTURE OF G`LAZED CERAMIC BODIES original Filed Nov. 29, 1938 n 7 sheets-sheet s April 25, 1944. G.. J. BAIR- MANUFACTURE OF GLAZED CERAMIC BODIS 7 Sheets-sheet 4 Original Filed Nov. 29, 1958 R el MK a c w EM ww n M MMT /E H G April 25,1944.

G. J. BAIR MANUFAGTURE OF GLAZED CERAMIC BODIES original Filed Nov. 29, 195s 7 sheets-sheet 5 @Y 604,14/ figg. @T7-ORNE prj, Q- G. J. BNR

MANUFACTURE OFl GLZED CERAMIC BODIES Original Filed Nov. 29, 1938 H7 Tok/WSH Patented Apr. 25, 1944 MANUFACTURE F GLZED CERAM() BODIES George J.

Bair, Pittsburgh, Pa., assigner to Norbert S. Garliisch original applieaiion Noventa-.29, 193s, serial No. 242,944. Divisas ami i appiieaiien .rune i5,

1949, Serial No. 340,753

6 Claims.

The present invention relates to processes of forming and glazing ceramic bodies and it has particular relation to such processes and apparatus as are applicable to the formation of 'and glazing of tiles or similar bodies from Waste sand produced in the grinding and polishing of glass.

One object of the invention is to provide a process of the foregoing type which operates substantially continuously and requires a minimum number of heating operations in` the formation of the completed product.

It has heretofore been the practice in the grinding and polishing of glass to cement the plates thereof to the top of movable carsor tables, and then to spread sand' in water suspension over the surfaces tov be polished while simultaneously passing them under revolving discs, termed runners. Gradually the surfaces were worn away and simultaneously the particles of sand were broken down into finer and ner state. Ultimately a very intimate mixture of extremely fine (about to 2G microns) particles of silica and glass was obtained. This mixture contained about -25 per cent of glass, the rest being mainly silica. vision and for other reasons the mixture has heretofore been discarded as of no Value.`

Recently it has been suggested that the mixture might be heated to the sintering point of the glass particles contained therein and then subjected to pressing in a suitable mold. As a result of this treatment the particlesof silica and glass were bonded together to form strong coherent bodies suitable foi` use as ceramic tiles, or for similar purposes.

The bodies as initially obtained possess porous, or more or less grainy, surfaces somewhat resembling an ordinary unglazed tile which for most purposes requires a glaze. Conventional methods of glazing such as are employed in connection with ordinary clay tiles suggest themselves. However, it will be recognized that the steps of forming a clay tile involve preparing plastic blanks of moist clay and then drying and ring the blanks in saggars stacked in kilns. t

also necessitate the expenditure of excessive amounts of fuel.

It has now been found that by employing the waste sand from the grinding andA polishing of Because of .its fine state of (ii- (CF. liti-JH glass as a source of material for ceramic bodies taken in a horizontal plane along the lines I-I of Fig. 2, of an apparatus embodying the process of the invention.

Figure 2 is a View partially in elevation and `partially in cross-section,- taken substantially Figure 3 is a fragmentary View partially in" elevation and partially in cross-section of a molding and pressing mechanism suitable for use in forming coherent blanks from waste sand.

Figure 4 is a fragmentary cross-sectional view taken in vertical plane, showing in greater detail mechanism for applying pulverized glazing material to the tile blanks.

Figure 5 is a fragmentary cross-sectional view takenvin a horizontal plane substantially upon the line V-V of Fig. 4.

Figure 6 is a cross-sectional View taken in a horizontal plane substantially along the line VI-VI of Fig. 7, showing a modified form of apparatus.

Figure 7 is a view partially in elevation and partially in cross-section, substantially-upon the line VII- VII of Fig. 6.

Figure 8 is a cross-sectional view substantially upon the line VIII-VH1 of Fig. 7.

Figure 9 is a fragmentary isometric view of a mechanism for pushing tablets or briquettesof waste sand into the forming press.

Figure 10 is an^ elevational detailed view of a cam mechanism for controlling the various operations of the apparatus.

In the form of the invention shown in Figures 1-5 inclusive circular base I5 is formed with upwardly-extending ribs I6 constituting tracks for fianged rollers l'l. The rollers also receive and support downwardly-extending ribs i8 of an annular conveyor ring I9 that supports a series of molds 20. These molds are formed with cavities 2l of appropriate size and contour in which are disposed follower plates -22, designedvto exhopper (not shown).

tract the blanks after formation. Each plate is vattached to a vertical .rod 23 extending downwardly through the mold and having upon its @wer extremity a roller 24 which engages at an appropriate stage in the travel of the ring I9, with a cam 25 to raise the plate.

Rotary motion` is imparted to the ring byl a ypivoted pawl 28, adapted to engage gear -teeth 3| upon the outer periphery of the ring in such manner that upon reciprocation of the rod, the ring is rotated in steps corresponding in linear length to the spacing vof the molds.

Waste sand for forming the tile blanks may be supplied to the molds fronra feed mechanism such as a chute 32 extending to a suitable feed The sand may be fed into the molds in loose state or, if preferred, it may be admixed with a binder such as molasses, tar, water-glass, or the like, to form plastic masses which may be subdivided into tabletsor briquettes of-appropriate size for the preparation of the bodies.

A tunnel kiln 33 incloses an appropriate sector of the ring 9 and is provided with suitable l burners (not shown) by-means of which the waste sand material contained in the molds may be heated to the sinteringtemperature of the glass content of the waste sand mixture.

A press for shaping and consolidating the waste sand into coherent masses in the molds comprises a base 36, to the upper portion of which is attached a vertically disposed cylinder 31 having conduits 38.. A plunger 39 reciprocates within the cylinder and is adapted to register with molds 20 and when -the plunger is actuated downwardly it functions toc ompress material within the mold disposed therebeneath.

The blanks 4| are removed from the follower plate 22 by means of a mechanism which includes a piston 42 reciprocating in a cylinder 43 which conveniently may be: disposed in the base 36 of the pressand which is supplied with actuating fluid for the piston by conduits 44.

A plate 41 receives .the freshly formed blanks and directs them upon the upper reach of a conveyor belt 48, having its receiving end adjacent to the press and trained about rollers 49, one of which is driven by motor mechanism 50. Preferably the conveyor is formed of heat-resistant material, for example, of a mesh of chromium steel links. The upper reach of the belt upon which the freshly. formed blanks are disposed `passes through a preheating tunnel within which is disposed a series of burners 52 for heating the blanks to anappropriate temperature for glazing.

As shown in Figs. 4 and 5 mechanism for receiving the preheated blanks from the conveyor belt 48 includes a grid or platform 58 comprising a series of spaced parallel bars 54 disposed adjacent to the extremity of kiln 5I Preferably the bars are water cooled, for example By means of a conduit 56 contacting therewith and connected at its extremities with supply conduits 51, for the admission and withdrawal of cooling fluid.

A cylinder 58 for fluid under compression is disposed in parallelism with respect to the preheating kiln 5| and a piston 59 reciprocates therein. This piston at its forward extremity is provided with a cross-head 6U, through which extends an arm 6| that projects laterally through slot 62 into the kiln at the extremity thereof. The arm may be of hollow construction and include an inlet conduit 63, for 'the admission of cooling fluid and an outlet 64. Arm 6| includes a downwardly-extending finger 65 which, as the piston 59 advances, rides up and over the top of the tile blanks, but as the piston is retracted it engages the rear edges of the blanks to carry them forward upon the platform 53.

As the blanks traverse the platform, dry, pulverized, glazing material is distributed thereupon by means of a mechanism that includes a supply hopper 66 carried by a framework 61. At its lower extremity the hopper discharges into a feed chute` 68,.which is supported upon parallel spring leaves 69 and 1|, the latter of which carries vibrator 12 for imparting a rapid vibratory motion thereto. Such motion carries the crushed material along the chute and discharges it into a vertical chute 13. At its lower extremity chute 13 terminates adjacent to the upper surface of a blank .ulpon the platform. A receptacle 15 is disposed beneath the'platform to receive any material which is not deposited upon the surface of the tile and which drops between the bars of the platform.

A cover plate 16, through which chute 13 extends, is supported between kiln 5| and a second fwith the drums 49 by motor mechanism 80.

This conveyor extends through tunnel kiln 11 above mentioned and burners 8| within the kiln at the rear extremity thereof play upon the tile blanks, thus insuring ladequate fusion of the glazing material. The burners 8| are so regulated as to obtain gradually decreasing temperatures in the direction of travel of the glazed bodies. Proper annealing is thus obtained.

The mode of operation of the construction described is substantially as follows:

When the mold carrying ring I9 .is at rest, the molds 20 are charged through the chute 32 with waste sand in appropriate amount to form the tiles or other blanks which are to be produced. The sand may be cold or if preferred it may be preheated to any appropriate degree, e. g., 1000 F., in order to reduce' the amount of heat' necessary to be added in the furnace 33, in order to sinter the glass particles. As previously stated, the wastesand may also be added in the form of coherent tablets or briquettes obtainable by mixing the material in dry state with a binder such as water-glass and then subdividing it into masses of appropriate size and dried. If tablets or briquettes are fed into the molds, they may be preliminarily coated with lime or other dusting material, in order to prevent possibility of adhesion to the molds.

The molds are successively indexed past the charging station by reciprocation of the piston rod 25 in the cylinder 26 until the one first charged reaches the press 36. During passage through the kiln 33 the material is heated to l about 16 or 17 hundred degrees`F. The mold on emergence from the kiln is brought into register with the plunger 2l and fluid is admitted to the cylinder 31 in order to actuate the plunger downwardly to compress the material. Thedegree of pressure employed to effect satisfactory consolidation of the mass preferably isv relatively high. Good results have been obtained by employment of a pressure of about 4000 to 6000 pounds per sq. inch of surface area of the blank under compression. Higher pressures may be employed and the upper limit is determined only by the capacity of the apparatus. Pressures as low as 1000 pounds per sq. inch or thereabouts are f' also contemplated. The method of application of the pressure may be relatively short, for example, 1-10 seconds, though shorter or longer periods are also applicable if so desired. A brief hammer-like impact upon the material is also contemplated as being within the scope of the invention.

After a block has been properly compressed the plunger is withdrawn and the mold is indexed to bring the next mold into register with the press.. The rotation ofthe ring 2| engages the roller 24 with the cam 25 to lift rod 23 and the follower plate 22, thus elevating the freshly formed coherent blank to the level of the top of the mold.v

Piston rod 42 is then actuated to push the freshly formed blank from the mold across the plate 41 to the upper reach of the conveyor belt 40. The latter carries the blanks in succession y 'under the burners 52 to preheat them to the desired temperature for glazing. When a blank reaches the end of the preheating tunnel 5|, fluid under compression is admitted to the cylinder 50 to actuate the piston rod 59 forwardly and the ringer l5 then drops over the front edge of a preheated blank. When fluid under compression is admitted to the other end of the cylinder 40 to retract the piston rod, the blank is drawn from the belt upon the platform 52 and moves under the lower end of the chute 1 3. Glazing material in pulverized form is fed downwardly through the chute and sprinkled over the surface of the blank in a relatively uniform layer. It is probable that a certain degree of sintering of the glazing material occurs immediately upon contact with the blank. However, in order to insure perfect 1 sintering the blank is pushed by the plunger from the platform upon conveyor 10 -which then conducts it under burners 0|. After the'glazing material has been properly fused or sintered the blanks pass through the cooler zones of the chamber 11 where the temperature is gradually reduced in order to anneal the bodies. Subsequently the Lbodies are removed from the forward end of the kiln.

The' chilling of the grid or platform 52 by glazing conduit 5l obviates. any tendency of any material striking it to fuse thereto. 'Ihe material simply falls through into pan 15 where it can be removed. In the form of theinvention illustratedin Figures 6-10 inclusive the press 00 for forming the blanks is provided with a base 9| having a platen 92 upon which rests a mold 94, having a cavity 96 of appropriate dimensions for the articles to be formed. Cavities 91 are also formed in the mold and suitable burners of heating elements 90- are disposed therein' for purposes of maintaining the mold at a suitable working temperature.

Blanks after they have been pressed vin the mold are ejected by means of a follower plate 99 upon a piston rod which projects Vupwardly through the mold. The rod at its lower extremity is attached to a piston head |02 within a cylindrical cavity |03, which cavity is supplied 'with fluid under compression by means of conduits Pressure is applied to the material' within the mold by plunger |00 upon the lower extremity of a piston rod |01 which reciprocates 'within 10 vertical cylinder |08 upon theupper extremity of the base 9|. At opposite extremities this cylin-v -der is connected with conduits |09 and for the admission of actuating fluid.

Preheated material (waste sand) may be supplied to the press, for example in the form of tablets or briquettes H2 of approximately the same cross-section as the mold cavity 95. vIf they are not of a size suicient almost completely to fill the mold, difficulty may be experienced in the pressing operation, because the material will not flow laterally to any substantial degree. The tablets are supported upon slab ||3a and are passed through a preheating tunnel kiln i3,

which is provided with burners (not shown), by

mechanism including a rod H4 having combined reciprocal and rotative movement within the kiln. The rod as shown in Figures 6 and 9 has appropriately spaced laterally-extending fingers ||6 adapted to engage the rear edges of the tab'- lets and thus to move them in steps through the kiln. f

Reciprocatory motion is'transmittedto the rod by means 'of a piston ||1fupon the rear extremity thereof, which piston reciprocates within 1acylinder H8, having conduits ||9 at opposite extremities thereof for the admission of actuating fluid. The stroke of the piston corresponds to the spacing of the fingers H0, thus insuring that aftera briquette has been advanced by one finger it will be engaged by the succeeding finger during th'e next stroke.

Rotation ofthe rod fory purposes of alternately lowering the fingers IIB to engage thel rear edges of the briquettes ||2 during forward mvement thereof, or to clear the edges during retraction of the rod is effected by an arm |2|,

which is splined upon the shaft, within a bifur' cated portion m of a bearing bracket m.' The extremity of the armis pivoted as indicated at |24 to a piston rod |20 which reciprocates in cylinder |21 having conduit connections |20 for fluid under compression.

, The freshly formed blanks are removed from the follower plate 00 by means of a piston rod |30 which reciprocates in cylinder |3| having conduits |32 for tluid under compression.

Blanks pass from th follower plate across an apron |33 to a belt I3 which is encircled by a system of parallel, spaced wires |31. The wires and the conveyor will be described in greater detail in due course.

Conveyor belt |36 and forward portions of wires |31 are trained about rollers |38 having bearings |39 supported by frame-work |40, of tunnel kiln |4|, adapted to reheat the freshly formed blanks for the vsubsequent; enameling or glazing operation. As shown in Fig. 8, the space between the reaches of the conveyor belt'is closed by means of sections |42 which are supported by .channel-like rails |43, that rest on brackets-|44,

which in turn are attached to frame |40 by bolts |45. s

As vshown in Figure 8, conveyor |36 comprises transverse bars |46 with slots for wires |31. At their extremitieathe bars extend through slots |41 between the edges of closures |42 and the adjacent edges of the walls of the kiln and are interconnected by a drive-chain |48, including links |49 and rollers |5I. The rollers of the upper reach of the chain ride upon the upper edges of rails |43, and those of the lower reach ride upon the upperl edge of a rail |52 of L-shape cross section, which at its extremities is secured to the frame |40,

For purposes of actuating the chain intermit tently tofdrive the conveyor, a cylinder |53, having conduits |54 for actuating fluid, is secured upon the kiln and isprovided with a piston rod |55. At its extremity, the piston rod is attached to a cross-bar |56 of a carriage |58. Wheels or rollers |59 are secured to the sides of the carriage and are disposed in channel-like members |6| mounted upon rails |62, of frame |40..

Side plates |63 and |64 are also secured to the sides of the carriage |58 and terminate at their luwer edges adjacent to the conveyor chains |48. Pawls |66 pivoted as indicated at |61 to the plates |63 and |64 provide a connection between the plates and the links of 'the chains. Longitudinally adjustable plates |61a may be disposed above the chains in position to lift the pawls from the chains during a part of the stroke of piston |54. By adjustment of these plates the length of the effective stroke of the pawls may be regulated.

It will be observed that wires |31 extend through kiln |4| and pass through mechanism for glazing the tiles. The mechanism includes a feed hopper |68, supported by uprights |69 upon a second section of kiln I4 The hopper discharges into a feed trough |1| which is supported sections |4| and |10.

The temperature 'of the bodies is maintained during the glazing operation by 'a cover plate |11 through which chute |14 extends. If desired, burners |18 may also be disposed in proximity to the discharge end of the chute.

'I'he operation of the feed trough |1| is synchronized with the movements of the conveyor |36 and wires |31 by suitable control mechanism involving an upwardly-projecting extension |19 of plate |63, which extension carries a horizontal flange or rib |8|, having at its forward end a pawl |82, which at its free end normally rests upon a second-horizontal flange |83. A roller |84 at the extremity of the switch arm |85 travels upon the flanges as the carriage |58 oscillates, being deflected by pawl |82 to pass over the flange 8| during' forward movement `of the carriage. During the return stroke it drops down upon flange |83.

The switch arm is pivoted as indicated at |81 to.p1ate |88 which is mounted upon bar or beam |62. An arm |89 is, also, secured to the switch arm and at its upper end is provided with a flexible connection |9| joined to electrical conductor |92. The extremity of the arm is provided with a contact point |98 having lead |94 to vibrator |13. The latter is further connected by lead |96 tc a suitable source of electrical current in order to energize the vibrator.

The wires |31 extend through section |10 of the furnace and pass in proximity to a series of burners |91 adapted to heat the tiles to such temperature as completely to fuse down the vglaze into a smooth uniform coating. 'I'he burners 91 may be so regulated as to obtain gradually decreasing temperatures in the direction of travel of the bodies, thus insuring that the latter will be properly annealed. Externally of the end of the section |10, the wires |31 are trained about a roller |99 journaled in 'bearings 20|, disposed upon frame |40.

The return' reach of the wires is also trained over a pair of horizontally spaced idler rollers 202, journaled in the supporting framework, of the kiln. Between the idler rollers loops 203 of the wire are trained about take-up rollers 204, which are designed to maintain the wires under uniform tension at all times.

As shown in Figure l0, mechanism for controlling the cycle of operation of the various elements of the assembly, including the cylinder ||8, pressure cylinder |08, cylinder |03, cylinder |21, cylinder |3| and cylinder |53, includes a shaft 201, which is journaled at its extremities in uprights 208. The shaft at one extremity is connected to the shaft 209 of a speed-reducing mechanism or gearing 2| which in turn is driven by a suitable electrical motor 2 l2.

Cams 2|3 of appropriate outline are disposed upon the shaft, there being a cam for each conduit of the pressure cylinders herein described.

-'I'he cams contact with rollers 2 |4 having bearings in the lower extremities of slides 2 I6 of valves 2 1, which valves in turn are suitably connected by conduits 2|8 to the conduits of the variouspressure cylinders. It will be apparent that as the shaft 201 is rotated the various valves are operated in sequence by the cams 2 I 3, in order to obtain the desired cycle of operations of the various elements in the mechanism.

The mode of operation on the mechanism is substantially as follows: Briquettes of waste sand are fed into the tunnel preheating kiln |3 in any convenient manner and are advanced in steps through the latter by means of the rod ||4 and 5 the side arms ||6 carried thereby. At the time the briquettes reach the mold 94 it is desirable that the follower plate 99 be in elevated position and the piston or plunger |30 be retracted. The briquette is `then advanced upon the follower which is subsequently retracted by rod 0| to lower the briquette into position in the mold.

The plunger |01, upon actuation, compresses'I the briquette into a dense strong coherent mass which upon admission of fluid to the cylinder |03 is .elevated by the follower plate to the level of the top of the mold. Actuation of plunger |30 pushes the freshly formed body upon the-conveyor |36 and wires |31 where it is carried under the pre-- heating burners in order to raise it to the glazing temperature. As each body is deposited upon the conveyor the piston rod is oscillated in order to advance -the conveyor an appropriate step. When the blanks reach the extremity of the kiln |4 they are carried by wires |81 under the chute |14 during the cycle of operation of the vibrator |13. As a result a uniform' layer of pulverized glazing material is deposited upon the upper surface of the blank. By reason of their small size, the wires after they emerge from the furnace quickly, cool to such extent that stray glazing material striking them falls into the pan below without fusing to them.

'In successive steps of operation of the conveyor the blanks having the pulverized material thereupon pass under burners |91. the heat of which fuses the material down to a uniform coating. In the further advance of the bodies they are carried into thev cooler zones of the section lil where they are gradually cooled in order to anneal them. The bodies upon emergence upon the section are in iinished form and may be removed for storage or packing.

It will be apparent that the process as herein disclosed is peculiarly adapted for the production of tiles or similar bodies from waste sand or such like materials comprising a hard, infusible but pulverulent material admixed with a fusible material such as glass. Such material may be preheated to the temperature required for pressing. Then when still hot it can be removed immediately from the press as a body of suilicient rigidity to admit of handling and glazing. At most, slight 'reheating to bring it to the glazing temperature is all that is required. Accordingly, it is feasible to apply dry pulverized glaze to the bodies as they are received from the press and then by a short heating operation adequately to fuse down the l glaze into a uniform coating.

This in direct contrast to conventional processes of forming ceramic bodies from lclay in which the bodies are rst formed from moist material and must then be dried, red and cooled before glazing material can be applied. Such process almost of necessity requires prolonged iiring operations with the bodies in saggers or trays.

Various glazes are applicable in the process.

-However, one that will fuse down at a temperature below about 1700 F. is to be preferred. Enamels such as are applicable to cast iron are particularly adapted for .the purpose. The following is an example of such enamel:

Silica 32.0 Salt peter 6.0 Soda ash 7.5 Borax 9.5 Red lead 39.5 Coloring (FezOs or the like) 5.5

be applied and fused down sumciently for immediate annealing. The further application of heat after application of the glaze may then be obviated.

'Ihe present application is a division of applicant's application Serial No. 242,944, filed November 29. 1938, now issued as Patent 2,264,499, as oi' December 2. 1941.

What I claim is:

1.' A process of coating ceramic bodies, obtained by heating to a temperature, above the sintering point of glass, a mixture of i'lnelydivided silica and glass resulting from the grinding and polishing oi plate glass and consisting of about 10 to 25 per cent of glass and the rest being essentially silica, all components of the mixture being groundto a neness such that nearly all of it will pass through a screen of about 325 mesh, subjecting the mixture to a shaping operation in a mold under a pressure of about 1000 pounds per square inch and upward to adhere the particles of glass with the particles of silica, thus forming hard, strong and coherent ceramic bodies, which process comprises withdrawing the bodies from the molds and while they -are still hot applying thereto a coating of glazing material, maturing the glaze and annealing the bodies.

2. A process as deilned in claim 1 in which the glazing material is sprinkled onto the bodies in dry, nely divided state.

3. A process as dened in claim 1 in which the pulverized mixture is heated to a temperature of about 1600 to 1700 F.

4. A process as deilned in claim 1 in which the pulverized material is prellminarily formed into briquettes before heating and shaping.

5. A process of forming a. mixture of finely divided silica and glass resulting from the grinding and polishing of glass with waste sand into glazed ceramic bodies, said process comprising heating the material to the sintering point of the glass therein in small portions corresponding to the nished bodies, pressing the portions successively in order to compact them and shape them into desired form and to effect coherence into hard, strong, dense masses, passing each body as itis received from the pressing operation through a heating kiln, sprinkling pulverized glazing material upon the bodies as they are received from the kiln, and while sufficiently hot to fuse down the glazing material.

A. process of forming tile-like ceramic bodies, which process comprises heating a mixture of about to 90 per cent of very iinelydivided silica and 10 to 25 per cent of nnelydivided glass, resulting from the surfacing of glass with sand-as an abrasive, and further comprises depositing appropriate amounts of the heated mixture in a mold and strongly pressing f the hot mixture in order to cohere the particles of glass to the particles of silica and thus to form strong, dense bodies,\removing the pressed bodies from the molds and moving them successively, as formed, away from the mold, and while they are being moved and are still hot sprinkling a pulverized glazing material thereupon, the temperature of the bodies being suilicient to fuse the glazing material into a uniform adherent coating upon the bodies and subsequently cooling and annealing the bodies.

GEORGE r. BAIE. 

